Pallet conveyors, tracking & AGV interfaces
Software architecture, programming and commissioning of a pallet transport system connecting new conveyors, AGV transfer points, manual stations and existing equipment.
Client task
Connect new pallet conveyors, AGV transfer points and the existing transport system while maintaining pallet data tracking.
My responsibility
I developed the software architecture, PLC/HMI, tracking and routing logic, interfaces and safety software, and performed testing and commissioning.
Result
Approximately 30 conveyors integrated with new and legacy equipment, with pallet transport, routing and data tracking implemented.
Technical solution and scope
System scope
Approximately 30 accumulation conveyors, two AGV interfaces, four manual in/out stations, four legacy conveyor interfaces, six turntables, Siemens drives, S7-1200 and five HMI panels.
My responsibility
I developed the complete software architecture, PLC program, tracking/routing logic, AGV and legacy interfaces, HMI and safety software, and handled testing and commissioning. Another company provided mechanical/electrical design and installation.
The challenge: multiple loads, one drive
Long accumulation conveyors used one common drive with up to three tracking positions. FIFO data, rear gap/front stop sensors, falling-edge gap detection and adjacent-conveyor readiness kept pallet information synchronized with physical movement.
Data and interfaces
Pallet ID, product, quantity, destination, route, status and position were tracked. Data entered through AGV/legacy handshakes or manual input. Interfaces included transfer permissions, readiness, busy states and faults. AGV work covered interfaces, not autonomous navigation software.
HMI and safety
Five HMIs provided equipment/pallet states, data entry/correction, routes, alarms and tracking recovery tools. Safety programming covered guards, controlled access, light grids with muting and scanner/LiDAR protection near pedestrian areas.
Commissioning and result
The new system was commissioned independently before connection to legacy lines that remained operational. Pallet transport, routing and data tracking were implemented across the mixed new/legacy equipment environment.
Have an automation project?
Describe the equipment, project stage and result you need. We can establish where my engineering experience will be most useful.